Multi fluid heat exchanger assembly

ABSTRACT

The present invention relates to coplanar multi fluid heat exchanger assemblies comprising a heat exchange core, end tanks and in tank oil coolers. Oil is preheated by coolant by in tank oil coolers leading to advantages in overall thermal performance.

FIELD OF THE INVENTION

This invention relates to heat exchanger assemblies, and methods forforming heat exchangers assemblies, and, particularly, heat exchangersassemblies employing multi-fluid heat exchangers.

BACKGROUND OF THE INVENTION

It has become increasingly desirable for heat exchangers to exhibitefficient transfer of heat, while remaining relatively easy to make. Inthe automotive industry, in particular, it has become increasinglynecessary to combine multiple functions in a single heat exchangerassembly. In particular, the need to reduce the number of overallcomponents, and to optimize assembly efficiency has driven the need forimproved heat exchanger assembly devices that combine increasinglyefficient designs and multiple functions in packaging heretoforeattainable using plural separate components or devices havinginefficient designs. More specifically, there has been a growing needfor an improved heat exchanger assembly device, particularly for underthe hood automotive vehicle applications, which combines multiplefunctions, that is efficient to make and operate and that occupiessubstantially the same or less space than existing heat exchangerassembly devices.

In prior art heat exchangers, fluid warm up is often needed for specificlength of time, and bulky arrangements to provide for in tank oilcoolers and separate heat exchangers allowing warm fluid to exchangeheat with fluid to be warmed have been used. In all of the cases thearrangement is not compact and heat exchange capacity is limited. Forexample, traditional systems require additional heat exchanger assemblyto cool oil for high performance conditions (trailer tow or highperformance engines). The typical solution has been to provide foradditional separate heat exchanger assemblies, usually air to oil heatexchanger assemblies, with resultant cost and packaging issues.

In the automotive industry, there has existed for some time, the need toprovide these multiple advantages at reduced service and other operatingcosts. Prior art multi-fluid heat exchangers, for example, include heatexchangers with in-tank oil coolers, but with a main core area that onlyhandles one fluid, for example, in a radiator, a radiator coolant. Therehas also been a need for heater exchange assemblies and systems withconfigurations whereby not only cross-flow but also down flowconfigurations are both possible and feasible. Additionally, althoughcombo coolers present advantages such as condenser to oil combinationsto handle individual heat exchanges in a combined form, it may not meetcertain vehicle needs. In automotive applications, fluids such asautomotive fluids (oils, coolants, refrigerants, fuels, windshield wiperfluids, brake fluids, air, CO2, exhaust gasses and the like) are oftenused, and have different chemical and thermodynamic characteristicsmaking them useful as heat exchange fluids. Particularly in extremeoperating conditions and where a multi-fluid heat exchanger or ‘combocooler’ assembly presents advantages, it is seen as particularlyattractive to be able to selectively manage heat exchange between thedifferent fluids, especially when the different fluids passed throughthe heat exchanger assembly have substantially different flowcharacteristics. The present invention provides solutions for a numberof the limitations found in traditional heat exchanger assemblies.

SUMMARY OF THE INVENTION

The present invention allows coplanar multi fluid heat exchangerassembly and systems to offer higher capacity automotive fluid,including oil cooling option. The present invention solves the problemof the prior art by allowing, for example, for both reduction of costand simplifying packaging difficulties by providing additional capacityby linking in tank cooler to air to oil cooler as part of a coplanararrangement.

The present invention allows one to use a separate radiator withdifferent temperature zones while allowing other fluid to be heated orcooled by a separate in tank or partially integrated heat exchangeelement. FIGS. 2 and 3 shows the example where first fluid is radiatorcoolant and second fluid and third fluid, if selected also to beradiator coolant, then the heat exchanger assembly will be a multi zoneradiator. This link of both heat exchange functions is often describedas a method to provide optimal cooling.

In preferred embodiments, the present invention allows for the use of acombination cooler (combo cooler) for non-air conditioned cars, as wellas air conditioned equipped cars depending on choice and configurationof components and its zones. The present invention also provides fordown flow configuration where packaging and layout makes the fluid flowalmost in vertical direction.

The present invention allows in-tank heat exchanger assembly to warm thefluid inside them with radiator coolant. Allows higher capacity totransfer heat for second fluid if needed in a compact coplanar heatexchanger assembly arrangement is provided.

The present invention allows for the use of a wide variety of fluids andtypes of fluid for heat exchange in one assembly. By placing a number offluids or types of fluid in various zones or areas of a heat exchangerassembly, preferably in a coplanar arrangement, fluids in such heatexchanger assemblies such as radiator coolant, transmission oil andpower steering oil, and the like, surprisingly provide efficiencies andpackaging advantages, as well as yielding combination cooler plusadditional heat exchanger assembly (‘tri-cooler’)(three fluid) or dualor multiple combination cooler (combo cooler plus additional heatexchange) features, which were unavailable even with traditional combocooler technologies.

The present invention meets the above needs by providing an improvedheat exchanger assembly without the same packaging limitations as thecondenser and oil cooler combinations of traditional combo cooler by:providing radiator packaging advantages; by having fewer oil cooler linerouting limitations; by providing reduced service costs forcondenser-oil coolers; by allowing use of combination cooler typetechnology for non-air conditioned cars; and, by functioning wheredown-flow configuration needs to be used.

More specifically the present invention allows for a heat exchangerassembly having more than one ‘zone’ in its various heat exchange areasin order to conduct heat exchange for multiple fluid at different rates.The main ‘core’ area is comprised of a heat exchanger core comprising aplurality of tubes and a plurality of fins disposed between the tubes,wherein at least one fluid, and, in particular, an automotive fluid,flows. The core area conducts heat exchange for one or more fluids atdifferent rates. More preferably, the present invention allows for twoor more zones in the main core area of the heat exchanger assemblywherein one or more fluids exchange heat at same or different rates ineach zone.

The heat exchanger assembly of the present invention, outside of thecore area, also provides for at least one zone of where heat exchangeutilizing fluids, and, preferably, automotive fluids, occurs. Mostpreferably the heat exchanger assembly has at least one, and,preferably, at least two almost parallel end tanks having a heatexchange element in at least one of the end tanks. This in-tank heatexchange element, (e.g. a cooler in the end tank or manifold area of theheat exchanger assembly) provides for at least one heat exchange zoneoutside of the core area zones, the heat exchange element utilizing afluid, and, preferably, an automotive fluid, to provide for anexchanging leading to the heat exchange zone.

The present invention provides for multiple fluids to flow in coplanararrangement, without the disadvantages of the prior art and withincreased efficiency due to the exchange of certain fluids in certainzones of the heat exchanger assembly, and between zones of the heatexchanger assembly, while also reducing packaging volumes, therebyreducing packaging restraints. In preferred embodiments of the presentinvention, a heat exchanger assembly is provided that comprises at leasttwo zones in the main core area and at least one or more separateexchange elements in at least one end tank (or, likewise known as amanifold) of the heat exchanger assembly. The heat exchanger assemblymore preferably has at least two in tank heat exchange elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic view of a multiple fluid heat exchange of theprior art.

FIG. 2 is a schematic face on view of a heat exchange assembly with intank heat exchange element in accordance with an aspect of the presentinvention.

FIG. 3 is a schematic face on view of a heat exchange assembly with withthree core zones and in tank heat exchange element in accordance with anaspect of the present invention.

FIG. 4 is a schematic face on view of a heat exchange assembly with intank heat exchange element in one compartment in accordance with anaspect of the present invention.

FIG. 5 is a schematic face on view of a heat exchange assembly with intank heat exchange element partially within or integrated into at leastone or two compartments in accordance with an aspect of the presentinvention.

FIG. 6 a is a schematic view of a heat exchange assembly system withheat exchanger assembly and other heat exchanger in accordance with anaspect of the present invention, with heat exchange zones in parallel.

FIG. 6 b is a schematic view of a heat exchange assembly system withheat exchanger assembly and other heat exchanger in accordance with anaspect of the present invention, with heat exchanger assembly and otherheat exchanger side by side.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention, therefore, in its preferred embodiments, byproviding for at least two or more zones in the main core area and atleast one or two more other zones outside of the core area and, inparticular, in at least one end tank, and, preferably, in at least onecompartment of at least one end tank, provides for a wider applicationrange of for heat exchanger assemblies by providing hereintoforeuntapped capabilities for heat exchange (and, in particular, ‘cooling’)using three or more different types of fluid, preferentially four ormore different types of fluids. In preferred embodiments of the presentinvention, a zone or zones may be achieved by providing a heat exchangerassembly with at least one heat exchange element in one of or each ofthe two collecting or ‘end tanks’ of heat exchanger assembly with a corecomprising a radiator. In such preferred embodiments by providing a heatexchanger assembly having a heat exchange element in the collecting orend-tank of the heat exchanger, pre heating of the heat exchange fluid,and, particularly automotive fluid, can be achieved through the heatingof radiator fluid. Also preferred embodiments of the present inventioncan provide even more efficiencies by providing for a coplanar heatexchanger assembly in combination with or ‘on top of’ heat exchangerassembly with two collecting tank, whereby additional exchange or‘cooling’ with one more different fluid occurs. The present invention,therefore, allows for the incorporation of smaller heat transfercapacity heat exchangers in the collector tanks and better (moreefficient) (smaller volume) packaging is achieved for an equivalentamount of heat exchanger capacity for the assembly as a whole.

The zones for heat exchange are generally located in both the core ofthe heat exchange assembly and in at least one of the end tanks of theassembly. In preferred embodiments of the present invention wherein theheat exchanger assembly is particularly suited for an automotivevehicle, the assembly comprises a first end tank; at second end tank; acore including fins, a least two compartments in the at least one of theend tanks; at least two heat exchange zones the core each including aplurality of spaced apart tubes with fins between the spaced tubes; andat least one heat exchange element in at least one of the end tanks. Theheat exchange zones are disposed so that their respective tubes and finsare generally co-planar with each other and are connected to the endtank.

The present invention, therefore, relates to a heat exchanger assemblyand a heat exchanger assembly system employing more than one heatexchange element in the end tank of the heat exchanger assembly. Theheat exchanger assembly is a multi-fluid (e.g., 3 or 4 fluid) heatexchanger. More preferably the heat exchanger assembly of the presentinvention utilizes two or more different types of fluids, morepreferably three or more different types of fluids. By different type offluids, it is meant fluids with different thermodynamic characteristicsof heat transfer useful for different heat applications in an automotivevehicle. The heat exchanger assembly may also be a one pass per zone ormulti-pass heat exchanger. Although the heat exchanger assemblyaccording to the present invention may be used for a variety of articlesof manufacture (e.g., air conditioners, refrigerators or the like), theheat exchanger assembly has been found particularly advantageous for usein automotive vehicles. In preferred embodiments of the presentinvention, the heat exchanger assembly may be used for heat transfer ofone or more automotive fluids. More preferably, the heat exchangerassembly may be preferentially used for heat transfer of one or moredifferent types of fluids, and include, restriction fluids such outsideof the end-tank such as air, oil, transmission oil, power steering oil,radiator fluid, refrigerant, combinations thereof or the like. Forexample, in a highly preferred embodiments of the present inventionthere is contemplated a multi-fluid heat exchanger assembly with a heatexchanger core area that includes zones, that due to their heatexchanger characteristics that can be seen as: a radiator in combinationwith a condenser; a radiator in combination with an oil cooler selectedfrom the group consisting of a power steering oil cooler, a transmissionoil cooler and a combination thereof; or a radiator in combination witha condenser and an oil cooler selected from the group consisting of apower steering oil cooler, a transmission oil cooler and a combinationthereof.

According to one preferred aspect of the invention, the heat exchangerassembly with a heat exchanger core area provides an improvedmulti-fluid heat exchanger assembly having features permitting for easeof assembly of the heat exchanger. According to another preferredaspect, the heat exchanger assembly heat exchanger core area isoptimized for performance by careful selection of such design criteriaas hydraulic diameter, tube configuration or a combination thereof.

The heat exchanger assembly may be installed in a variety of locationsrelative to the article of manufacture to which the heat exchangerassembly is applied. For an automotive vehicle, the heat exchangerassembly is preferably located under a hood of the vehicle, especiallyin areas where maximum air flow can be experienced in the vehicle (whichis usually in the front of the vehicle), but may, in some cases be atthe bottom or in the rear, or in electric vehicles in the side of thevehicles. According to one highly preferred embodiment, the heatexchanger assembly may be attached to a radiator of the vehicle.Exemplary methods and assemblies for attaching a heat exchanger assemblyto a radiator are disclosed in U.S. Pat. No. 6,158,500 and U.S. PatentPublication WO03/069251 titled “A Method and Assembly for Attaching HeatExchangers”, filed Feb. 10, 2003, both of which are fully incorporatedherein by reference for all purposes.

According to one aspect of the invention, the heat exchanger assemblywill comprise a plurality of components that are assembled together bysuitable joining techniques. Many techniques may be utilized, includingmechanical assemblies and the like. In one preferred embodiment, one ormore of the components of the heat exchanger assembly such as thebaffles, the end tanks, the tubes, fins, the inlets, the outlets, abypass or combinations thereof may be attached to each other usingbrazing. Although various brazing techniques may be used, one preferredtechnique is referred to as controlled atmosphere brazing. According toone highly preferred embodiment, a brazing alloy may be provided as acladding on one of the components of the heat exchanger. In such asituation, it is contemplated that the components may be formed of amaterial such as a higher melting point aluminum alloy while thecladding may be formed of a lower melting point aluminum alloy.

The heat exchanger assemblies of the present invention are useful inautomotive or motor vehicle applications. Heat exchangers assemblies ofthe present invention will typically include core components such as oneor more tubes, one or more end tanks, one or more inlets and outlets,one or more baffles and other core components such as one or more finsor a combination thereof. In the present invention, the at least one ormore end tanks, have at least one or more heat exchange elements in atleast one or more of the end tanks, and, preferably, in at least one ormore compartments of at least one or more end tanks. Depending upon theembodiment of the heat exchanger assembly, various different shapes andconfigurations are contemplated for the components of the assembly. Forexample, and without limitation, the components may be integral witheach other or they may be separate. The shapes and sizes of thecomponents may be varied as needed or desired for various embodiments ofthe heat exchanger. Additional variations will become apparent uponreading of the following description.

In general, a preferred heat exchanger assembly contemplates at leasttwo spaced apart end tanks bridged together by a core with at least twozones, in at least partial fluid communication by a plurality ofgenerally parallel tubes, with fins disposed between the tubes. Optionalend plates, or more preferably, end tubes, enclose the core assembly ina generally co-planar configuration. At least one of the end tanks, and,preferably, both of the end tanks, have at least one heat exchangeelement therein wherein heat exchange takes place between two fluids.

The multiple-fluid heat exchanger assembly, due to the inclusion of atleast one heat exchanger element, and, preferably, more than one heatexchange element within at least one of the end tanks, handles more thanone fluid in coplanar arrangement with smaller packaging size thantraditional combo coolers and with larger heat exchange capacity.

In preferred embodiments of the present invention, a heat exchangerassembly comprises: a first end tank; a second end tank opposite thefirst end tank; a plurality of first tubes in fluid communication withthe first and second end tanks, the plurality of first tubes adapted tohave a first fluid flow therethrough; a plurality of second tubes influid communication with the first and second end tanks, the pluralityof second tubes adapted to have a second fluid, flow therethrough; aplurality of fins disposed between the first and second tubes, with thefirst and second tubes and the fins being generally co-planar relativeto each other; a heat exchange element adapted to have a third fluid,different from the first or the second fluid, flow therethrough; whereinat least one of the first fluid or second fluid is a radiator fluid, andwherein the third fluid is an automotive fluid. More preferred is whenthe heat exchange element is located in the first or second end tank andthe first end tank and the second end tank each include at least onebaffle.

Also preferred are heat exchanger assemblies having at least twoseparate heat exchange elements in either one or both of the first orsecond end tanks. More preferred are heat exchanger assemblies whereinat least one of the separate heat exchange elements is located in thefirst end tank and at least one of the separate heat exchange elementsis located in the second end tank.

Heat exchangers assemblies as described herein, utilize automotivefluids capable of heat exchange, including cooling. Where thirdautomotive fluids are used, they can, preferably, depending on desiredapplications, be radiator fluids or oils. The present invention extendsthe applicability with radiator coolant as one of the fluid inconjunction with transmission oil or power steering oil or engine oil orany other fluid requiring heat transferred.

In further preferred embodiments of the present invention, the heatexchanger assembly comprises: a first end tank; a second end tankopposite the first end tank; at least one heat exchange element in atleast one of the end tanks; a plurality of first tubes in fluidcommunication with the first and second end tanks, the plurality offirst tubes adapted to have an automotive fluid flow therethrough; aplurality of second tubes in fluid communication with the first andsecond end tanks, the plurality of second tubes adapted to have anautomotive fluid, flow therethrough; a plurality of third tubes in fluidcommunication with the first and second end tanks, the plurality ofthird tubes adapted to have an automotive fluid, flow therethrough; anda plurality of fins disposed between the first, second and third tubes,with the majority of fins being generally co-planar relative to eachother. More preferably, each plurality of tubes and the heat exchangeelement each form an area or zone of heat exchange of the heat exchangeassembly. The these preferred embodiments, at least one automotive fluidflows through the area or zone of the heat exchanger assembly, as wellas, in preferred embodiments, through the zone of the heat exchangeelement in the end tank. In even more preferred embodiments, where thereis at least one of first, second or third tubes. At least one of thefirst, second or third tube is adapted to have a radiator fluid flowtherethrough.

The tubes of the core of the heat exchanger assembly can be the same orof different size from one another. Preferred is wherein at least one ofthe first tubes, second tubes or third tubes is of another size than oneof the other tubes. Particularly when at least one of the first, secondor third tubes is of another size than one of the other tubes, it ispreferred that the first or second tubes have an oil flowingtherethrough. Particularly preferred is where first and second tubes arepresent in the core and the heat exchange element is in the end tank,that in at least one of the first or second tubes and the at least oneheat exchange element are adapted to have a radiator fluid flowtherethrough.

As mentioned, one advantageous feature of the present invention is theability to integrate a plurality of different fluid heat exchangefunctional elements. Though the specification will make apparent thatalternatives are possible (e.g. side by side), one particularlypreferred configuration for the components of the assembly is toeffectively stack a first fluid heat exchanger element or area upon atleast a second fluid heat exchanger element or area in a singlegenerally co-planar assembly. In another particularly preferred approacha first fluid heat exchange element or area is stacked upon at least asecond fluid heat exchange element or area and a third fluid heatexchanger. More preferred is that the at least first, second and thirdheat exchange elements or areas are in a single generally co-planerassembly. Also more preferred is a stacked at least first, second andthird heat exchange element or area in a crossflow or horizontalassembly. In more preferred embodiments of the present invention, theheat exchange zones may be described by the functions that they perform.For example, where automotive fluids such as oils pass or flowtherethrough they are referred to oil heat exchange zones, wherecondenser or related coolant fluids pass or flow are referred to ascondenser zones, where radiator fluids pass or flow as radiator zones.In more preferred embodiments of the present invention, the heatexchange zones are selected from the group consisting of an oil heatexchange zone, a condenser zone, a radiator zone or combinationsthereof. For example, in preferred embodiments of the present invention,at least one of the heat exchange zones functions as a radiator.

Another advantageous feature of the present invention is the ability topresent the integration of the plurality of different fluid heatexchange elements or areas with zones as a heat exchanger assemblysystem. Particularly preferred is a heat exchanger assembly systemwherein one heat exchange element or area is adapted to have a fluidselected from the group of radiator coolant and an automotive fluid andthe other heat exchanger assembly is adapted to have a fluid selectedfrom the group of automotive fluids. Another particularly preferredembodiment is a heat exchange element or area wherein the heatexchangers are arranged essentially in parallel. Another particularlypreferred embodiment is a heat exchange element or area wherein the heatexchange elements or areas are arranged side by side.

In particularly preferred embodiments of the heat exchanger assembly ofthe present invention, both cross flow or horizontal and down flow fluiddirection may occur. Even more particularly preferred embodiments ofheat exchanger assemblies of the present invention are those wherein thefluid flow direction is vertical or ‘down flow’ from top to bottom orbottom to top.

Referring to FIG. 1, a prior art heat exchanger is shown with arrowsindicating fluid flows.

Referring to FIGS. 2 and 3, a heat exchanger assembly 200 or 300 isshown with two separate in-tank heat exchange elements (203/204 or304/305) with a core area (201/202 or 301/302/303) having at least twozones in coplanar arrangement.

Referring to FIG. 2 heat exchanger assembly 200 has a one piece ormultiple piece first tank 221; a second tank 222 comprises one piece ormultiple pieces opposite the first tank; a plurality of first tubes 201is in fluid communication with the first and second end tanks 221, 222,the plurality of first tubes adapted to have first fluid flowthere-through, for example, between ports 205 and 206; a plurality ofsecond tubes 202 is adapted to have a second fluid, different from thefirst fluid or the same fluid in embodiments with cores such as thosefound in ‘combinations’ such as low temperature or high temperatureradiators, flow there-through, for example, ports 207 and a plurality offins disposed between the first and second tubes, with the first andsecond tubes and the fins being generally co-planar relative to eachother.

The first tank 221 and second tank 222 each have two compartments 218and 216 for tank 221 created by separation 213. Compartments 219 and 217for second tank 222 are created by separation 214. Compartments 216 and217 are in fluid communication for first fluid. Compartments 218 and 219are in fluid communication with second fluid.

Compartment 219 is further separated by a separation 215 to createcompartment 220 and 223. The second fluid is in fluid communication withcompartment 220-218 and 218-223. The second fluid is externallycommunicated through port or manifold type 208 or regulator type device207.

The first tank 221 incorporates heat exchange element (in tank cooler)203 inside forming a zone in tank 221 in compartment 216 and third fluidflows inside heat exchange element 203 and third fluid is either cooledor heated by the first fluid flowing in the first tank in communicationwith second tank 222. Similarly second tank 222 also incorporates orhouses in tank cooler 204 forming a zone in compartment 217, and fourthfluid flows in communication between first tank 221 and second tank 222to exchange heat with the inside heat exchange element 204 and thefourth fluid is either cooled or heated by the first fluid flowing inthe second tank 222 in communication with first tank 221. FIG. 2 showsfour different heat exchange element arranged to manage at least fourfluids.

It is understood that in some applications at least one of the in tankoil coolers can be removed thereby leaving only one tank housing in tankoil cooler (preferably the tank which is downstream of the fluid whichis heating or cooling the in tank cooler fluid).

The same arrangement as was discussed above is in FIG. 2 can beenvisioned in downflow arrangement if rotated 90 degrees.

Referring to FIG. 3 more than four fluids are present through the heatexchanger assembly design and FIG. 3 shows an arrangement where 5different fluids are present.

Heat exchanger assembly 300 comprises one piece or multiple piece firsttank 329; a second tank 328 comprising one piece or multiple piecesopposite the first tank; a plurality of first tubes 301 in fluidcommunication with the forming a zone in compartment 330 of the firsttank 329 and zone in compartment 331 of the second end tank 328, theplurality of first tubes adapted to have first fluid flow there-through,for example between ports 307 and 306; a plurality of second tubes 302adapted to have a second fluid there-through, the second fluid the sameas, or preferably different from, the first fluid, and a plurality offins disposed between the first and second tubes, with the first andsecond tubes and the fins being generally co-planar relative to eachother.

The first tank 329 and second tank 328 each have at least threecompartments with at least zones in respective compartments. Zones arein compartments 330 and 331, compartments 320, 330 and 326 for firsttank 329 created by separations 315 and 318, and compartments 321, 331and 327 for second tank 328 are created by separations 314 and 317.

Compartments 330 and 313 are in fluid communication for fluid one.Compartments 320 and 321 are in fluid communication with second fluid.Compartments 326 and 327 are in fluid communication for fluid three.

Compartments 320 and 321 are in fluid communication with second fluid.Compartment 321 is further separated by a separation 316. The separation316 creates sub compartments 322 and 323 in compartment 321. Secondfluid is in fluid communication between compartment 322 and 320 and alsobetween zone 323 and 320. The second fluid is externally communicatedthrough port or manifold type 333 or regulator type devise 313.

Compartment 326 and 327 are in fluid communication for fluid three.Compartment 326 is further separated by a separation 319. The separation319 creates sub compartments 324 and 325 in compartment 326. Third fluidis in fluid communication between compartment 326 and 324 and alsobetween compartment 326 and 325. The second fluid is externallycommunicated through port or manifold type or regulator type device 312.

In one embodiment of the present invention, first tank 329 incorporatesanother heat exchange element 304 forms a zone in compartment 330, andfourth fluid flows inside heat exchanger assembly 304 which allowsfourth fluid to exchange heat with first fluid. Heat exchange elements(in tank coolers) are similarly illustrated in second tank 328 whichincorporates or houses in tank cooler 305 which allows fifth fluid toexchange heat with first fluid. FIG. 3 shows heat exchange elementsyielding heat exchanger assembly capable of handling at-least 5 fivefluids.

Preferred embodiments of the present invention, therefore, can acheive,also with the arrangements per this inventions warm up of desired fluidalong with cooling at higher capacities.

Heat exchanger assembly for multiple fluids is provided to give largerheat transfer capability and with warm up capability is illustrated inFIG. 4.

Heat exchanger assembly 400 comprises one piece or multiple piece firsttank 420; a second tank 421 one piece or multiple piece, opposite thefirst tank; a plurality of first tubes 401 in fluid communication withthe compartment 418 of the first tank 420 and zone in compartment 419 ofthe second end tank 421, the plurality of first tubes adapted to havefirst fluid flow there-through, for example between ports 403 and 404. Aplurality of second tubes 402 is adapted to have a second fluid,different from the first fluid, flow there-through, and a plurality offins disposed between the first and second tubes, with the first andsecond tubes and the fins being generally co-planar relative to eachother.

The first tank 420 and second tank 421 each have at least twocompartments. Compartments 418 and 412 for first tank 420 created byseparation or baffle 411. Compartments 419 and 414 for second tank 421are created by separations baffles 413.

Compartments 418 and 419 are in fluid communication for fluid one.Compartments 414 and 412 are in fluid communication with second fluid.

Second tank 421 incorporates another heat exchange element 423 incompartment 419 and second a fluid flows inside heat exchange element(in tank cooler) 423 which allows second fluid to exchange heat withfirst fluid.

The second fluid flows through in tank cooler 423 and exchanges heatwith first fluid in zone in compartment 419 and communicates throughport 406. Port 406 is either part of in tank cooler 423 or separate partor part of the tank 421. The port 406 is in communication with regulatordevice with manifold 410. The regulator devise is equipped sensors fortemperature or pressure or both.

When second fluid communicates between port 406 and 407 the second fluidis in warm up mode. Thus second fluid exchanges heat with fluid one incompartment with zone 419 through in tank cooler 423 and warms up, thensecond fluid passes through port 406, and depending on the regulatorsettings, exits out of port 407.

The second fluid flowing through in tank cooler 423 and after exchangingheat with fluid one; comes out at port 406 which is in communicationwith regulator devise with manifold 410. Depending upon the regulatortemperature or pressure setting or both, the second fluid passes throughthe manifold (end tank) and enters or communicates with compartment 414.The second fluid passes through a plurality of second tubes 402 whichare in fluid communication with zone 412 and exits at port 409. In thismode the second fluid is being cooled. The second fluid cools downthrough heat exchange with first fluid and is further cooled by externalfluid, for example, air, when it flows through a plurality of secondtubes 402. Higher capacity heat exchange is possible for the secondfluid as it has two different cooling fluids to exchange the heat, firstwith fluid one in the zone 419 and then with a third fluid, preferablyair, when flowing through a plurality of tubes 402.

In a particular preferred embodiments of the present invention, thefirst fluid is preferably radiator coolant, the second fluid ispreferably a transmission or engine oil.

416 and 422 are mounting pins crimped to the side plate 417, for laterbrazing. 415 is a drain cock in this embodiment.

Referring to FIGS. 4 and 5, a heat exchanger assembly is shown with 423and 523 providing for a zone in end tank compartment 419 wherein aselected automotive fluid, such as transmission oil or engine oil, canbe pre-warmed using heat exchange with fluid such as radiator coolantprior to entering in to compartment 414. This pre-warmed fluid goes backto the system. While, at the same time, once the fluid is warmed up topredetermined temperature the cooling of the fluid is required and thecooling takes place in zone in compartment 419 and the regulator devicewith manifold 410 allows the fluid to pass through and enter thecompartment 414 and further through core section 402 and gets cooledfurther prior to exit to return to system through 409.

FIG. 5 provides for a heat exchanger assembly for multiple fluids togive larger heat transfer capability.

Heat exchanger assembly 500 comprises a one piece or multiple piecefirst tank 520; a second tank 521 comprising of one piece or multiplepiece, opposite the first tank; a plurality of 419 first tubes 501 influid communication with the compartment 518 of the first tank 520 andzone in compartment 519 of the second end tank 521, the plurality offirst tubes adapted to have first fluid flow there-through, for examplebetween ports 503 and 504; a plurality of second tubes 502 adapted tohave a second fluid, different from the first fluid, flow there-through,and a plurality of fins disposed between the first and second tubes,with the first and second tubes and the fins being generally co-planarrelative to each other.

The first tank 520 and second tank 521 each have at least twocompartments. 518 and 512 for first tank 520 created by separation 511.Zone in compartment 519 and 514 for second tank 421 are created byseparation 513. The separation 513 is provided such that it isolatesfirst fluid from second fluid but has opening where heat exchangerassembly 523 can be positioned such that second fluid is in direct fluidcommunication with 514.

Compartments 518 and 519 are in fluid communication for first fluid.Compartments 514 and 512 are in fluid communication with second fluid.

The second tank 521 incorporates heat exchange element 523 (in tankcooler) and a second fluid flows inside in tank cooler 523 which allowssecond fluid to exchange heat with first fluid.

The second fluid flowing through in tank cooler 523 and after exchangingheat with fluid one, comes out at port 506 which is in directcommunication with zone 514. The second fluid passes through a pluralityof second tubes 502 which are in fluid communication with zone 512 andexits at port 509. In this mode the second fluid is being cooled. Thesecond fluid cools down through heat exchange with first fluid and itfurther gets cooled by external fluid which is usually air when it flowsthrough a plurality of second tubes 502. Higher capacity heat exchangeis possible for second fluid as it has two different cooling fluids toexchange the heat, first with fluid one in the zone 519 and then withfluid 3, preferably, usually air when flowing through a plurality oftubes 502.

In preferred embodiments of the present invention, preferred first fluidis radiator coolant, and a preferred second fluid is transmission orengine oil.

516 and 522 are mounting pins crimped to the side plate 517, which laterare brazed. Item 515 is a drain cock.

FIG. 6 illustrates preferred embodiments where heat exchange elements orareas or zones can be arranged in the vehicle parallel to each other orside by side. In FIGS. 6 a and 6 b, heat exchanger assembly 1000 isshown in combination with other heat exchanger 1000 to form heatexchanger systems.

In more preferred embodiments of the present invention, the heatexchanger assembly may be used in conjunction or in combination withanother heat exchanger or heat exchanger assembly. The at least oneother heat exchanger or heat exchanger assembly may be a single fluid ora multiple fluid heat exchanger or heat exchanger assembly, andcollectively, for the purpose of the invention, is described as a heatexchanger assembly system. Preferably the heat exchanger assembly systemcomprises a heat exchanger assembly and at least one other heatexchanger.

As described herein, preferred embodiments of the present invention,and, in particular those involving heat exchanger assembly systemswherein at least one zone of the heat exchanger assembly is adapted tohave a fluid selected from the group of radiator coolant and anautomotive fluid, the at least one other zone the other heat exchangerassembly is preferably adapted to have a fluid selected from the groupof automotive fluids. In preferred heat exchanger assembly systems, asin the preferred heat exchanger assembly of the system, the heatexchange zones are preferably arranged in parallel. Also in preferredheat exchanger assembly systems, preferred heat exchanger or heatexchange assemblies of such a system, are arranged so as the heatexchanger or exchangers and the heat exchanger asssembly are arrangedside by side.

In preferred embodiments of the present invention it is contemplatedthat the fluid flow direction in normal operational position of the heatexchanger assembly will be vertical or downflow from top to bottom orbottom to top. Also preferred are embodiments wherein the heat exchangeelement is partially within or integrated into at least one of thecompartments. Where heat exchange elements are partially within orintegrated into at least one of the compartments, it is preferred thatat least two separate heat exchange elements be integrated into at leasttwo compartments.

Preferred embodiment of heat exchanger assemblies described in thepresent invention use end tanks which are designed to handle automotivefluid, and, preferably, radiator fluid, and associated features forexample inlet and outlet sizes, attachment features etc. The shape andthe type of the end tanks can be circular, rectangular and any othershape and not limited to circular and rectangular as shown in thisinvention. The size and design will be dependent on radiator flowrequirements and maximum oil pressure limit.

Baffles for diverting the flow of same fluid are described in combocoolers, as well as baffles separating two fluids. The baffles in theheat exchanger assemblies (end tanks) meet the needs of specific crosssection of the end tanks.

The fins between the tubes can preferably be of the same type in theheat exchanger core area and is preferred most simplistic manufacturingscenario. In the event where different fins are required to meetindividual heat exchanger assembly needs such arrangement also can beused in the present invention.

It is contemplated that a heat exchanger assembly formed in accordancewith the present invention may include a core one or more tubes havingvarious different internal configurations for defining passagewayswithin the tubes. They may also have different external configurationsdefining one or more outer peripheral surfaces of the tubes. Further itis possible that the internal configurations, external configuration orboth vary along the length of the tube.

The internal configuration of a tube may be the same or different fromthe external configuration. For instance, the walls of the tubes mayhave opposing sides that are generally parallel to or otherwisecomplement each other. Alternatively, they may have a differentstructure relative to each other. The external configuration of the tubemay include grooves, ridges, bosses, or other structure along some orall of its length for assisting in heat transfer. Likewise, the internalconfiguration may include grooves, ridges, bosses or other structure. Itis also possible that the structure is provided for generatingturbulence within the fluid, or for otherwise controlling the nature ofthe flow of fluid there-through or for strength.

The passageways of the tubes may be provided in a variety of shapes suchas square, rectangular, circular, elliptical, irregular or the like. Inpreferred embodiments, the passageways of tubes may include one or morepartitions, fins or the like. As used herein, a partition for apassageway in a tube is a structure (e.g., a wall) that substantiallydivides at least part of the passageway into a first and second portion.The partition preferably is continuous (but may be non-continuous) suchthat the partition completely separates the first portion from thesecond portion or the partition may include openings (e.g.,through-holes, gaps or the like) connecting the first and secondportion.

As used herein, a fin for a passageway in a tube is intended toencompass nearly any structure (e.g. a protrusion, a coil, a member orthe like), which is located within the passageway of the tube and isphysically connected (e.g., directly or indirectly) to an outer surfaceof the tube that engages in heat exchange. The shape of each of the finsmay be the same or different relative to each other. Further, the pitchangle of each fin may be the same or different relative to each other.It will also be appreciated that the configuration of a tube may varyalong its length. One or both tube ends may be provided with fins butthe central portion left un-finned. Likewise, the central portion may beprovided with fins but one or both of the tube ends are left un-finned.Fin spacing may be constant within a passageway or may be varied asdesired.

It is contemplated that various numbers of partitions and fins may beused depending upon the size, shape, configuration or the like of thepassageways, tubes or both. The fins may be any desirable shape, forinstance they may have a sectional profile that is rectangular, roundedor the like. Preferably, the partitions can divide the passageways intovarious numbers of portions of various different sizes and shapes or ofsubstantially equivalent sizes and shapes. As examples, the portions maybe contoured, straight, rectangular or otherwise configured.

For certain applications, and particularly for lower viscosity fluids,it can be advantageous to have substantially equally sized passagewayssuch that flow through each of the passageway is substantiallyequivalent and promotes higher amounts of heat transfer. In alternativeembodiments, a tube may be divided into one or more of a plurality offirst passageways having a first sectional area and one or a pluralityof second passage ways having a second sectional area (e.g. larger,smaller of different shape relative to the first passageways).Additionally, the partitions of the tube may extend horizontally,vertically, diagonally, combinations thereof or otherwise.

Advantageously, tubes with passageways divided into larger and smallersub-passageways, such as those above, have the ability to effectivelyperform a passive bypass function particularly for the cooling ofrelatively high viscosity fluids flowing through the tubes. Inparticular, a higher viscosity fluid will typically be more viscous atlower temperatures and, consequently, more of the fluid will flowthrough the larger sub-passageways and bypass the smallersub-passageways resulting in less heat transfer from the fluid. Incontrast, as the temperature of the fluid elevates, the fluid willbecome less viscous and, consequently, the rate will increase at whichthe fluid is able to flow through the smaller sub-passageways. Thus, thediverse passageway structure tube facilitates, flow of the highviscosity fluid through the tube at cooler temperatures.

In other alternative embodiments, surfaces defining the internalportions of any of the internal passageways of the tubes may be smoothor planar or may be contoured such as corrugated (e.g., includingseveral patterned ridges), ribbed (i.e., including several protrusions),dimpled (e.g., including several depressions) or another suitable finstructure. Spiral or helical grooves or ridges may be provided. In stillother alternative embodiment, the tubes may include one or more internalinserts, which are fabricated separately from the tubes but subsequentlyassembled together. It is contemplated that inserts may be formed in avariety of configurations and shapes for insertion into passageways orportions of passageways of tubes. For example, and without limitation,inserts may be members (e.g., straight or contoured members) withcomplex or simple configurations. Alternatively, inserts may be coils,springs or the like.

Formation of tubes according to the present invention may beaccomplished using several different protocols and techniques. Asexamples, tubes may be drawn, rolled, cast or otherwise formed.Additionally, tubes according to the present invention may be formed ofa variety of materials including plastics, metals, carbon, graphite,other formable materials or the like. Preferably, however, the tubes area metal selected from copper, copper alloys, low carbon steel, stainlesssteel, aluminum alloys, titanium alloys or the like. The tubes may becoated or otherwise surface treated over some or all of its length forlocally varying the desired property.

In the tubes of the heat exchangers of the present invention, ahydraulic diameter in the range of desired hydraulic diameters ispreferred to obtain maximum effectiveness of the exchanger.

As used herein, hydraulic diameter (DH) is determined according to thefollowing equation:D _(h)=4A _(P) /P _(w)wherein

-   -   A_(p)=wefted cross-sectional are of the passageway of a tube;        and    -   P_(w)=wetted perimeter of the tube.

Each of the variables (P_(w) and A_(p)) for hydraulic diameter (H_(d))are determinable for a tube according to standard geometric andengineering principles and will depend upon the configuration of aparticular tube and the aforementioned variables for that tube (i.e.,the number of partitions, the number of portions, the size of theportions, the size of the passageways or a combination thereof).

Heat transfer and pressure drop for a fluid flowing through the tubescan be determined for a range of hydraulic diameters using sensors suchas pressure gauges, temperature sensors or the like.

For a multi-fluid heat exchanger, it may be desirable for the tubesdesigned to transport one of the fluids to be sized, dimensioned or bothrelative to the tubes that are designed to transport the other fluid[s].In particular, for a multi-fluid heat exchanger assembly designed tohandle a first fluid such as a radiator coolant and a second fluid suchas an oil (e.g., transmission or power steering oil), and a third fluidsuch as a refrigerant, it is desirable for the internal and externalsurface areas of the various tubes to be sized, dimensioned or bothrelative to each other to provide for greater amounts of heat transferto and/or from the fluids.

According to a preferred aspect of the present invention, a multi-fluidheat exchanger assembly includes tubes for transporting a first fluidsuch as a radiator coolant and tubes for transporting a second fluidsuch as an oil (e.g., transmission oil, power steering oil or the like)and tubes for transporting a third fluid such as condenser fluid (e.g.refrigerant, CO2, etc.). For the tubes transporting the radiator fluid,a large amount of thermal resistance to heat exchange is produced at theexternal surface of the tube relative to any amount of thermalresistance produced at the internal surface of the tube. However, forthe tubes transporting the oil, a large amount of thermal resistance isproduced at the internal surface of the tube relative to the any amountof thermal resistance produced at the external surface of the tube. As aresult, it is generally desirable for the tube transporting the radiatorfluid to have a larger external surface area relative to its internalsurface area while it is generally desirable for the tube transportingthe oil to have a larger internal surface area relative to its externalsurface area.

In certain embodiments of the invention, it is preferable for the heatexchanger assembly to include one or more end plates on the core forproviding protection to the tubes of the heat exchanger. The end platesmay be provided in various different configurations and may besubstantially planar or contoured, continuous or non-continuous orotherwise configured. Additionally, the end plates may be provided asseparate units that may be connected or attached to one or more of thecomponents (e.g., the end tanks) of the heat exchanger. Alternatively,the end plates may be provided as integral with one or more of thecomponents (e.g., the end tanks) of the heat exchanger.

According to one highly preferred embodiment, one or both of the endplates are omitted. The function of end plates is the end plates isprovided by end tubes instead. For example, the end tubes aresubstantially identical to one or more of the fluid carrying tubes ofthe heat exchanger.

The invention has been illustrated herein generally by reference to athree, four or five fluid heat exchanger. However, it is not intended tobe limited thereby. It is clearly contemplated that the inventivefeatures are adapted for providing even a heat exchanger assembly forfluids in addition to three fluids.

In one particular aspect of the present invention, it is preferable thatany baffle employed be generally disk-shaped (or otherwise conformsgenerally with an interior of the section in which it is introduced)with a first substantially planar outwardly facing surface opposite(either in spaced or in contacting relation with) a second substantiallyplanar outwardly facing surface. Preferably, the baffle includes acentral portion and a flanged peripheral portion. More preferred is abaffle system including a baffle or baffles with a central portion and(at least one) flanged peripheral portion, the flanged peripheralportion having a peripheral channel. Even more preferably, the bafflesystem comprises double baffles, i.e. a first and a second baffle beingassembled back to back with a common center contact portion.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible.

While a feature of the present invention may have been described in thecontext of only one of the illustrated embodiments, such feature may becombined with one or more other features of other embodiments, for anygiven application. It will also be appreciated from the above that thefabrication of the unique structures herein and the operation thereofalso constitute methods in accordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A heat exchanger assembly comprising: a first end tank; a second endtank opposite the first end tank; a plurality of first tubes in fluidcommunication with the first and second end tanks, the plurality offirst tubes adapted to have a first fluid flow therethrough; a pluralityof second tubes in fluid communication with the first and second endtanks, the plurality of second tubes adapted to have a second fluid,flow therethrough; a plurality of fins disposed between the first andsecond tubes, with the first and second tubes and the fins beinggenerally co-planar relative to each other; a heat exchange elementadapted to have a third fluid, different from the first or the secondfluid, flow therethrough, wherein at least one of the first fluid orsecond fluid is a radiator fluid, and wherein the third fluid is anautomotive fluid.
 2. A heat exchanger assembly as in claim 1 wherein theheat exchange element is located in the first or second end tank and thefirst end tank and the second end tank each include at least one baffle.3. A heat exchanger assembly as in claim 2 having at least two separateheat exchange elements.
 4. A heat exchanger assembly as in claim 3wherein the two separate heat exchange elements are located in one orboth of the first or second end tanks.
 5. A heat exchanger assembly asin claim 3 wherein at least one of the separate heat exchange elementsis located in the first end tank and at least one of the separate heatexchange elements is located in the second end tank.
 6. A heat exchangerassembly as in claim 2 wherein the third fluid is an oil.
 7. A heatexchanger assembly comprising: a first end tank; a second end tankopposite the first end tank; at least one heat exchange element in atleast one of the end tanks; a plurality of first tubes in fluidcommunication with the first and second end tanks, the plurality offirst tubes adapted to have an automotive fluid flow therethrough; aplurality of second tubes in fluid communication with the first andsecond end tanks, the plurality of second tubes adapted to have anautomotive fluid, flow therethrough; a plurality of third tubes in fluidcommunication with the first and second end tanks, the plurality ofthird tubes adapted to have an automotive fluid, flow therethrough; aplurality of fins disposed between the first, second and third tubes,with the majority of fins being generally co-planar relative to eachother; wherein each plurality of tubes and the heat exchange elementeach form an area or zone of heat exchange of the heat exchangeassembly; and, wherein at least one of the first, second or third tubeshas a radiator fluid flowing therethrough.
 8. A heat exchanger assemblyas in claim 7 wherein the at least one heat exchange element has anautomotive fluid flowing therethrough.
 9. A heat exchanger assembly asin claim 8 wherein the automotive fluid of at least one heat exchangeelement is an oil.
 10. A heat exchanger assembly as in claim 6 whereinat least one of the first tubes, second tubes or third tubes is ofanother size than one of the other tubes.
 11. A heat exchanger assemblyas in claim 7 wherein the first or second tubes have an oil flowingtherethrough.
 12. A heat exchanger assembly as in claim 7, wherein thefirst or second tubes and the at least one heat exchange element have aradiator fluid flowing therethrough.
 13. A heat exchanger assembly foran automotive vehicle, comprising: a first end tank; at second end tank;a least two compartments in the at least one of the end tanks; a core;fins; at least two heat exchange zones in the core each including aplurality of spaced apart tubes with fins between the spaced tubes; atleast one heat exchange element in at least one of the end tanks; theheat exchange zones being disposed so that their respective tubes andfins are generally co-planar with each other and are connected to theend tank; and the heat exchange zones being selected from the groupconsisting of an oil heat exchange zone, a condenser zone, a radiatorzone or combinations thereof.
 14. A heat exchanger assembly as in claim13 wherein at least one of the heat exchange zones functions as aradiator.
 15. A heat exchanger assembly system comprising a heatexchanger assembly as in claim 1 and at least one other heat exchanger.16. A heat exchanger assembly system comprising a heat exchangerassembly as in claim 7 and at least one other heat exchanger.
 17. A heatexchanger assembly system comprising a heat exchanger assembly as inclaim 13 and at least one other heat exchanger.
 18. A heat exchangerassembly system as in claims 15, wherein at least one zone of the heatexchanger assembly is adapted to have a fluid selected from the group ofradiator coolant and an automotive fluid and at least one other zone theother heat exchanger assembly is adapted to have a fluid selected fromthe group of automotive fluids.
 19. A heat exchanger assembly system asin claim 18, wherein the heat exchange zones are arranged in parallel.20. A heat exchanger assembly system as in claim 18, wherein the heatexchanger assembly and the at least one other heat exchanger arearranged side by side.
 21. A heat exchanger assembly as in claim 1wherein the fluid flow direction is vertical or downflow from top tobottom or bottom to top.
 22. A heat exchanger assembly as in claim 7wherein the fluid flow direction is vertical or down flow from top tobottom or bottom to top.
 23. A heat exchanger assembly as in claim 7wherein the fluid flow direction is vertical or down flow from top tobottom or bottom to top.
 24. A heat exchanger assembly as in claim 1,wherein the end tank having the at least one heat exchanger element hasat least two compartments and wherein the at least one heat exchangeelement is found in at least one of the compartments.
 25. A heatexchanger assembly as in claim 24, wherein at least one of the fluids ispreheated by heat exchange with the second fluid.
 26. A heat exchangerassembly as in claim 24, wherein at least one of the fluids is preheatedby heat exchange with the third fluid.
 27. A heat exchanger assembly asin claim 1, wherein the first end tank and the second end tank both haveat least two compartments and wherein the heat exchange element ispartially within or integrated into at least one compartment.
 28. A heatexchanger assembly as in claim 1, wherein the first end tank and thesecond end tank both have at least two compartments and wherein the heatexchange element is partially within or integrated into at least twocompartments.
 29. A heat exchanger assembly as in claim 25, wherein oneof the fluids which is being pre heated is controlled by a controldevice for its flow within the heat exchanger.
 30. A heat exchangerassembly as in claim 26, wherein one of the fluids which is being preheated is controlled by a control device for its flow within the heatexchanger.
 31. A heat exchanger assembly as in claims 29, wherein thecontrol device controls fluid access to more than one zone to increaseexchange cooling capacity.
 32. A heat exchanger assembly with more thanone zone, wherein at least one of the fluids of the heat exchangerexchanges heat in multiple zones to exchange heat at higher capacity.